Apparatus and method for forming retaining wall blocks with variable depth flanges

Abstract

A mold assembly including a plurality of mold components configured to form a mold cavity having a desired shape, at least one of the mold components having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth. The mold assembly further includes a moveable flange plate and a drive assembly configured to extend the moveable flange plate into and retract the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch.

1. A mold assembly, comprising:
 a plurality of mold components configured to form a mold cavity having a desired shape, at least one of the mold components having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth; 
 a moveable flange plate positioned at least partially within the at least one mold component and having a portion configured to extend into the notch via an opening in the at least one mold component; and 
 a drive assembly positioned within the at least one mold component and configured to extend the portion of the moveable flange plate into and retract the portion of the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch. 
 
   
   
     2. The mold assembly of  claim 1 , wherein the at least one mold component comprises a head shoe assembly. 
   
   
     3. The mold assembly of  claim 1 , wherein the at least one mold component comprises one of a plurality of liner plates. 
   
   
     4. The mold assembly of  claim 1 , wherein the drive assembly comprises:
 at least one first gear element selectively coupled to the moveable flange plate and having a plurality of substantially parallel angled channels; 
 a second gear element having a plurality of substantially parallel angled channels configured to slideably interlock with the angled channels of the at least one first gear element; and 
 an actuator selectively coupled to the second gear element and configured to apply a force in a first direction to the second gear element to cause the at least one first gear element to extend the moveable flange plate into the notch so as to decrease a depth of the notch, and configured to apply a force in a direction opposite the second direction to cause the at least one first gear element to retract the moveable flange plate from the notch as to increase the depth of the notch. 
 
   
   
     5. The mold assembly of  claim 4 , wherein the actuator comprises a dual-acting piston assembly. 
   
   
     6. The mold assembly of  claim 4 , wherein the actuator comprises a screw drive system. 
   
   
     7. The mold assembly of  claim 4 , wherein the drive assembly further includes a support element including at least one guide opening configured to slideably receive the at least one first gear element so as to stabilize and guide the moveable flange plate. 
   
   
     8. A mold assembly, comprising:
 a plurality of liner plates configured to form a mold cavity having a desired shape, the mold cavity having an open top; 
 a head shoe assembly having a major surface configured to be positioned within open top of the mold cavity, the major surface having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth; 
 a moveable flange plate positioned at least partially within the head shoe assembly and having a portion configured to extend into the notch via an opening in the major surface; and 
 a drive assembly positioned within the head shoe assembly and configured to extend the portion of the moveable flange plate into and retract the portion of the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch. 
 
   
   
     9. The molding assembly of  claim 8 , wherein the drive assembly comprises a gear drive assembly. 
   
   
     10. A mold assembly, comprising:
 a plurality of liner plates configured to form a mold cavity having a desired shape, wherein at least one liner plate is configured to form a bottom surface of a masonry block formed in the mold cavity, the at least one liner plate having a notch configured to form a set-back flange extending from the bottom surface of the masonry block, the notch having a depth; 
 a moveable flange plate positioned at least partially within the at least one liner plate and having a portion configured to extend into the notch via an opening in the at least one liner plate; and 
 a drive assembly positioned within the at least one liner plate and configured to extend the portion of the moveable flange plate into and retract the portion of the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch. 
 
   
   
     11. A mold assembly, comprising:
 a plurality of mold components configured to form a mold cavity having a desired shape, at least one of the mold component having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth; and 
 a flange assembly having a moveable flange plate positioned at least partially within the at least one mold component and having a portion configured to extend into the notch via an opening in the at least one mold component to selective adjust the depth of the notch.